Simulated woven fabrics

ABSTRACT

Fabric simulating woven fabric comprising conventional warp threads disposed in the longitudinal direction and a &#39;&#39;&#39;&#39;filling&#39;&#39;&#39;&#39; comprising monofilaments laid transversely of the warp threads but not woven over-and-under therewith. By extruding the monofilaments onto the warp threads as these latter advance past an extruding nozzle the warp threads and &#39;&#39;&#39;&#39;filling&#39;&#39;&#39;&#39; threads are caused to cohere or coalesce at their points of intersection to provide a fabric having enhanced tensile strength and flexibility in both directions. Moreover, the fabric may be produced at substantially lower cost than fabrics woven by conventional methods, e.g. on a needle loom or shuttle loom or by braiding, all of which are regarded as uneconomically slow. In one aspect the junctions of the &#39;&#39;&#39;&#39;filling&#39;&#39;&#39;&#39; threads and the warp threads at the selvages are so united as to yield a smooth edge. In still another aspect the invention is ideally suited to fabrics which are to have stretch characteristics either in the longitudinal or transverse direction, or both.

United States Patent 191 Miller 1 Feb. 18, 1975 I SIMULATED WOVENFABRICS [21] Appl. No.: 428,324

[52] U.S. Cl 161/57, 161/55, 161/60, l61/70,161/78,161/86,161/92,161/143,

161/149, 264/167, 264/DIG. 75

[51] Int. Cl B321) 5/12 [58] Field of Search 161/55, 57, 60, 70, 143,161/147, 149,78, 86, 92, DIG. 6; 264/103,

167, DIG. 75, DIG. 76, DIG. 81

[56] References Cited UNITED STATES PATENTS 2,738,298 3/1956 David etal. 161/143 3,140,973 7/1964 Johnson 161/92 3,419,456 12/1968 Tenney[61/78 3,597,300 8/1971 Miller 161/147 3,753,842 8/1973 Pittman 161/573,759,782 9/1973 Bleuer 161/57 Primary ExaminerWilliam J. Van BalenAssistant ExaminerWilliam R. Dixon, Jr.

57 ABSTRACT Fabric simulating woven fabric comprising conventional warpthreads disposed in the longitudinal direction and a filling comprisingmonofilaments laid transversely of the warp threads but not wovenoverand-under therewith. By extruding the monofilaments onto the warpthreads as these latter advance past an extruding nozzle the warpthreads and filling" threads are caused to cohere or coalesce at theirpoints of intersection to provide a fabric having enhanced tensilestrength and flexibility in both directions. Moreover, the fabric may beproduced at substantially lower cost than fabrics. woven by conventionalmethods, e.g. on a needle loom or shuttle loom or by braiding, all ofwhich are regarded as uneconomically slow. In one aspect thejlLlIlCtlOllS of the filling threads and the warp threads at theselvages are so united as to yield a smooth edge. In still anotheraspect the invention is ideally suited to fabrics which are to havestretch characteristics either in the longitudinal or transversedirection, or both.

17 Claims, 19 Drawing Figures SIMULATED WOVEN FABRICS BACKGROUND OF THEINVENTION Where, in the following description and claims, I employ theterms filling" or weft" the same are in-.

tended to refer to plastic filaments laid transversely of the warpthreads by extrusion but not interwoven therewith under-and-over in aconventional manner. However, depending upon the viscosity of theextruded material the monofilaments may become merged or coalesced withthe warp ends in varying degree. In accor dance with the invention somedegree of embedment of one thread with another at the points ofintersection is necessary in order that acceptable interlock of the warpand filling over the entire area of the fabric may be achieved.

Present methods of producing narrow fabrics, such as woven tapes andespeciallly elastic tapes, often are uneconomical and are far fromcommercially acceptable. In cases where the filling is resilient, e.g.nylon filaments, horsehair and the like, reversal of the lays of fillingat the selvages produces distinct arches which, due to the stiffness ofthe yarn, constitute rough edges. To counteract this the manufacturerintroduces a cushioning material which has the effect of filling in andcovering the arches. However, the cost of production is materiallyincreased thereby.

Additionally, in the case of stiff threads in the filling, breakage mayreadily occur and the broken end then protrudes beyond the selvage,obviously an objectionable resultv The same is true of the end of theyarn wound on a shuttle when it runs out.

The principal object of the present invention resides in the provisionof'a fabric, particularly a narrow fabric such as a tape which may beproduced at substantially reduced cost and has enhanced versatility. Forconvenience of nomenclature, a fabric in accordance with the inventionis referred to herein as a simulated woven fabric.

Another object is to provide a fabric as aforesaid wherein the warpthreads may be conventional yarns,

twisted or untwisted, natural or synthetic, monoor polyfilaments,elastic or non-elastic. Since the filling is c. those thermosettingplastic materials or mixtures thereof with thermoplastic materials,which are capable of extrusion;

d. wet spinnable materials, such as viscose, cuprammonium cellulose orprotein material (e.g. from soya beans), capable of extrusion andsetting by immersion in or spraying with a coagulant as the plasticemerges from the die.

SUMMARY OF THE INVENTION Material in accordance with the inventioncomprises a plurality of warp threads which are spaced apart someselected distance and are maintained in such spaced re lation by aplurality of transverse plastic filaments extruded onto the warp threadsas these latter advance past an extruding die. The extrusion process isso regulated that the warp threads and filling threads coalesce orcohere at their points of intersection whereby the flexibility of thefabric both longitudinally and transversely may be regulated.

Since it is desirable to attain a smooth aspect at the selvages, flow ofthe plastic material in such regions is necessarily controlled in amanner which avoids discontinuities or irregularities at the edges ofthe fabric.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an isometric view of a stripof fabric embodying the principles of the invention;

FIGS. 2, 3 and 4 are cross sections transversely of the fabric striptaken on the lines indicated compositely as 2-2, 3-3, 4-4;

FIGS. 5, 6, 7 and 8 are details in perspective of por tions of the weftfilaments to show various cross sec tions the same may assume;

FIG. 9 is asomewhat magnified, perspective view of a portion of thefabric showing the coalescense of the warp ends and weft filaments atthe selvage. In this figure the weft filaments are shown smaller thanthe selvage warp end;

FIG. 9a is a cross section taken on the line 9a-9a of FIG. 9;

FIG. 9b is a cross section taken on the line 912-912 of FIG. 9. In thisfigure the weft filaments are the same size as the selvage warp end;

FIG. 10 is a perspective view similar to FIG. 9 except that here theplastic forming the weft filaments is al' lowed to flow around andcompletely cover the selvage weft thread;

FIG. 10a is a cross section taken on the line 10a 10a of FIG. 10;

FIG. 11 is a perspective view similar to FIG. 9 except that in this casethe plastic forming the weft filaments does not flow axially along theselvage warp end but embraces it over an angle on the order of from 180to FIG. 11a is a cross section taken on the line lIa--l la of FIG. 11;

FIG. 11b is a cross section similar to FIG. except that in FIG. 11a thedepth of the weft filament is greater than the diameter of the selvagewarp end, while in FIG. 11b the depth of the weft filament is smaller;

FIG. 110 is a perspective view to show the relation of the selvage endand filling of FIG. 1111;

FIG. 12 is a perspective view showing a variation of FIG. 11 except thatthe weft filamentscompletely surround the selvage warp end; and

FIG. 12a is a cross section taken on the line 12a-12a of FIG. 12 toillustrate a condition wherein the portion of the Weft filamentsurrounding the selvage warp end is made quite thin.

DESCRIPTION OF THE PREFERRED EMBODIMENT Turning to the drawing there isshown a section 15 of fabric embodying the principles of the inventionillustrated, by way of example, as a strip comprising longitudinallyextending warp ends of any conventional form and material, monoormultifilaments and classified somewhat more specifically in theforegoing portion of this description. In the description and claimssuch warp ends may sometimes be referred to as threads constituting awarp.

At this juncture it will have become apparent that the terms warp andfilling are not used in the traditional sense but analogously thereto inthat the threads fed in the direction of movement of the web of fabricfunction similarly to the warp of a woven fabric and the transverselydisposed filaments function in somewhat the same way as the conventionalweft or filling threads which are interwoven with the weft in anover-andunder orientation.

In FIG. 1 the spacing of the filaments 16 is exaggerated for clarity ofexposition, it being understood that, in a practical construction, thisspacing is on the order of H32 inch. However, the disclosure is notintended to be limited to any specific spacing of the filamentsconstituting the filling. The ensuing description will be devotedlargely to particulars of the fused joints between the filling and warp,with special reference to the attainment of a smooth edge at theselvage. Such requirement becomes important when the invention fabrichas rubbing contact with an adjacent fabric; for otherwise significantabrasion of the latter can readily result.

Since, at the moment of extrusion, the plastic forming the filaments l6flows readily it is possible to control the coalescense of the filamentsand warp ends in a manner to reliably unite the two groups at theirpoints of intersection and to avoid any roughness or discontinuities atthe zones of junction, and as will now be described.

FIGS. 2, 3 and 4 illustrate some ways in which the aforesaid union maybe produced. FIG. 2 shows a condition in which the warp ends 17bdisposed intermediate the selvage warps 17a are only slightly embeddedin the filaments 16. FIG. 3 shows embedment in various degrees in orderto obtain various characteristics in the finished product. FIG. 4 showsembedment of the warp ends to a somewhat greater depth than is shown inFIG.

2. Further, from FIGS. 2, 3 and 4 it will be seen that the filaments 17have a cross section which is smaller than the mean diameter of theselvage warps 17a.'However, as will appear, the filaments may have across section which is larger than the mean diameter of the selvagewarps or may be equal. Moreover, as shown in FIGS. 5 to 8 the crosssection of the filaments may take various shapes e.g. circular,rectangular, triangular, or U- shaped. These and other cross sectionsare readily obtained by providing suitable transverse channels in a dieinto which, in one form of apparatus, the plastic may be extruded.

Since, in accordance with the principles of the invention, narrowfabrics may be produced without a shuttle or oscillating needle and theconsequent mechanical problems incident upon the behaviour ofreciprocating parts, the expense of maintenance and repair is materiallyreduced.

In order to provide a smooth or non-abrasive selvage various expedientsmay be availed of. Where, in this description and the claims, I employthe word selvage" I refer to the edge of the fabric as produced by themethod referred to herein and not to the nonraveling selvage of a fabricwoven by conventional techniques.

It will be understood that the apparatus for producing fabric embodyingthe principles of the invention will be provided with suitable means forcontrolling flow of the plastic in its molten state. If not regulated,overflow may occur at the ends of the filaments and a corresponding sawtooth edge produced. However, by proper choice of nozzle dimensions andaccurate control of the temperature, rate of flow and initiation andinterruption of flow, the edges of the fabric may take any of severalforms now to be described.

Adverting to FIGS. 9, 9a and 9b the filaments 16 are, at their ends,caused to flow to terminate in what may be termed a claw 21, embracingthe selvage warp ends 17a over an angle of from to 270 more or less, the

primary desideratum being to ensure that the extent of embrace besufficient to preclude separation of the selvage warp end and thefilaments. Thus, the nonembraced area, indicated as X in these figures,is the warp thread itself and, being smooth, will not abrade an adjacentfabric (not shown).

From FIGS. 9a and 9b it will be seen that the filaments 16 may be lessthan, equal to or greater than the selvage warps and of any crosssection (FIGS. 5 to 8).

Although the claw formations 21 are shown as fused at their adjacentends 20, it will be comprehended that slight separation is tolerablewithout introducing undesirable roughness at the selvage.

FIG. 10 illustrates a construction wherein the parameters regulatingflow of the plastic are so selected as to result in complete coverage ofthe selvage warps. In this case a continuous edge 25 is presented to theadjacent fabric (not shown). FIG. 10a shows the cross-sectional aspect.

The modification of FIG. 11 depicts a construction in which flow of theplastic is regulated in a manner similar to that of FIG. 9 except that,here, flow along and around the selvage warp end is restricted to thearea of abutment between the filaments 16a and the selvage warp.Although, in FIG. 11 the filaments 16a are illustrated as being ofrectangular cross section, these may, as previously pointed out inconnection with FIGS. 5 to 8, be of any desired cross section.

FIGS. 12 and 12a depict a modification which is similar to FIG. 11except that the portion of a weft filament shown as embracing theselvage warp is extremely thin in order not to produce objectionablelack of smoothness at the edges of the strip.

It is to be understood that the joint between the filament and warp endsmay encompass more than one end. Necessarily, this mode of joiningshould be confined to a zone closely adjacent to the edge of the fabric,for otherwise undesirable stiffness may be imparted.

It will be appreciated that either thermoplastic or thermal curingresins may be utilized for the weft filaments in accordance with thisinvention. Further, that a wide variety of resins may be used such as,vinyl chloride, vinyl acetate, vinylidene chloride, phenol, melamine, orurea aldehyde condensates, styrene and its copolymers with butadiene,acrylonitrile, acrylic resins, acrylonitrile resins, polyethylene,natural rubber, neoprene, and various other elastomers.

Where the fabric is to be longitudinally stretchable, elastomers areparticularly advantageous for the warp ends. If two-way stretch isrequired, both the warp ends and weft filaments will be elastomeric. Asan alternative, elastomeric warps may be alternated with nonelastomericwarps which are fed under little or no tension. In one commercial formthe warp ends were a spun polyester. However, the warps may be amonofilament fed singly or in multiple, twisted or untwisted. It ispossible to combine elastic weft filaments with nonelastic warp ends,both selvage and intermediate. Elastomeric warp ends will, necessarily,be fed to the point of extrusion under tension.

The invention also comprehends a fabric wherein the weft filamentsintersect the warps at an angle other than 90. Moreover, the weftfilaments may be welded to the warp threads by heat or ultrasonicradiant energy to supplement coherence naturally occurring by reason ofthe plasticity of the extruded material. In connection with any of thesesteps the warps may be preheated to improve the bond.

In producing one form of the invention on an experi mental basis theselvage warp ends comprised twisted polyester fibers. A die was providedwith two grooves spaced apart the same distance as the selvage warp endswhich latter were fed from sources of supply, e.g. bobbins. The warpends were each received in respective grooves and carried beneath anextrudinghozzle having an exit opening of narrow, elongated form, thelonger dimension of which was less than the distance between the selvagewarp ends. The die was also provided with a set of transverse groovesmeeting the other series of grooves and the plastic was extrudedintermittently in timed relation with the relative movement of thetransverse grooves past the nozzle exit whereby to form the weftfilaments. By reason of the pressure applied to the plastic issuing fromthe nozzle the plastic is forced toward the selvage warp ends to improvethe union of the weft filaments therewith and as described in connectionwith FIGS. 11, 11c and 12. The excess of molten plastic deposited in thetransverse grooves was wiped flush with the die by a doctor blade.Following this the warp ends intermediate the selvage warp ends werelaid across the still plastic weft filaments and roller pressure appliedto insure positive cohesion at the points of meeting and intersection.

Where, herein, I employ the term intersection in relating the weftfilaments to the warp ends I intend, in the interest of conciseness, torefer not only to intersections in the sense ofcrossing but the meetingof the filaments with the warp ends in a butt joint.

I claim:

1. In a fabric simulating woven fabric comprising a plurality ofparallel threads disposed in one direction to constitute a warpincluding a selvage warp thread at each edge of the fabric and aplurality of parallel filaments of plastic material disposed in adirection intersecting said threads to constitute a filling, saidrespective pluralities being joined at their points of intersection, theimprovement wherein the juncture of the filling filaments with theselvage warp threads are constituted as a butt joint and are smoothlymerged into the selvage warp threads whereby the selvages aresubstantially free of irregularities.

2. Fabric in accordance with claim 1 plastic material is thermoplastic.

3. Fabric in accordance with claim 1 plastic material is thermosetting.

4. Fabric in accordance with claim 2 thermoplastic is a polyamide.

5. Fabric in accordance with claim 1 warp threads comprise a polyester.

6. Fabric in accordance with claim 1 warp ends comprise an elastomer.

7. Fabric in accordance with claim 1 wherein the filling threadscomprise an elastomer.

8. Fabric in accordance with claim 1 wherein the warp ends and fillingthreads comprise an elastomer.

9. Fabric in accordance with claim 6 further characterized in that theelastomer is wrapped with a conven' tional yarn.

10. A fabric simulating woven fabric comprising a plurality of parallelthreads disposed inone direction to constitute a warp including aselvage warp thread at each edge of the fabric and a plurality ofparallel filaments of plastic material constituting a filling disposedin a direction intersecting said threads, said respective pluralitiesbeing joined at their points of intersection, the filling threads at thepoints ofjuncture with the selvage warp threads being smoothly mergedinto the selvage warp threads, the place ofjuncture constituting a buttjoint, whereby the portions of the filling filaments at the selvages arefree of irregularities.

11. Fabric in accordance with claim 10 wherein the plastic material isthermoplastic.

12. Fabric in accordance with claim 10 wherein the plastic material isthermosetting.

13. Fabric in accordance with claim thermoplastic is a polyamide.

14. Fabric in accordance with claim warp threads comprise a polyester.

15. Fabric in accordance with claim warp ends comprise an elastomer.

16. Fabric in accordance with claim filling threads comprise anelastomer.

17. Fabric in accordance with claim 10 wherein the warp ends and fillingthreads comprise an elastomer.

=l l l= wherein the wherein the wherein the wherein the wherein the 11wherein the 10 wherein the 10 wherein the 10 wherein the

1. IN A FABRIC SIMULATING WOVEN FABRIC COMPRISING A PLURALITY OFPARALLEL THREADS DISPOSED IN ONE DIRECTION TO CONSTITUTE A WRAPINCLUDING A SELVAGE WRAP THREAD AT EACH EDGE OF THE FABRIC AND PLURALITYOF PARALLEL FILAMENTS OF PLASTIC MATERIAL DISPOSED IN A DIRECTIONINTERSECTING SAID THREADS TO CONSTITUTE A FILLING, SAID RESPECTIVELYPLURALITIES BEING JOINED AT THEIR POINTS OF INTERSECTION, THEIMPROVEMENT WHEREIN THE JUNCTURE OF THE FILLING FILAMENTS WITH SELEVAGEWRAP THREADS ARE CONSITITUTED AS A BUTT JOINED AND ARE SMOOTHLY MERGEDINTO THE SELVAGE WRAP THREADS WHEREBY THE SELVAGES ARE SUBSTANTIALLYFREE OF IRREGULARITIES.
 2. Fabric in accordance with claim 1 wherein theplastic material is thermoplastic.
 3. Fabric in accordance with claim 1wherein the plastic material is thermosetting.
 4. Fabric in accordancewith claim 2 wherein the thermoplastic is a polyamide.
 5. Fabric inaccordance with claim 1 wherein the warp threads comprise a polyester.6. Fabric in accordance with claim 1 wherein the warp ends comprise anelastomer.
 7. Fabric in accordance with claim 1 wherein the fillingthreads comprise an elastomer.
 8. Fabric in accordance with claim 1wherein the warp ends and filling threads comprise an elastomer. 9.Fabric in accordance with claim 6 further characterized in that theelastomer is wrapped with a conventional yarn.
 10. A fabric simulatingwoven fabric comprising a plurality of parallel threads disposed in onedirection to constitute a warp including a selvage warp thread at eachedge of the fabric and a plurality of parallel filaments of plasticmaterial constituting a filling disposed in a direction intersectingsaid threads, said respective pluralities being joined at their pointsof intersection, the filling threads at the points of juncture with theselvage warp threads being smoothly merged into the selvage warpthreads, the place of juncture constituting a butt joint, whereby theportions of the filling filaments at the selvages are free ofirregularities.
 11. Fabric in accordance with claim 10 wherein theplastic material is thermoplastic.
 12. Fabric in accordance with claim10 wherein the plastic material is thermosetting.
 13. Fabric inaccordance with claim 11 wherein the thermoplastic is a polyamide. 14.Fabric in accordance with claim 10 wherein the warp threads comprise apolyester.
 15. Fabric in accordance with claIm 10 wherein the warp endscomprise an elastomer.
 16. Fabric in accordance with claim 10 whereinthe filling threads comprise an elastomer.
 17. Fabric in accordance withclaim 10 wherein the warp ends and filling threads comprise anelastomer.